CN105636734B - From the system and method that voltage and current feedback extracts arc length - Google Patents
From the system and method that voltage and current feedback extracts arc length Download PDFInfo
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- CN105636734B CN105636734B CN201480056382.8A CN201480056382A CN105636734B CN 105636734 B CN105636734 B CN 105636734B CN 201480056382 A CN201480056382 A CN 201480056382A CN 105636734 B CN105636734 B CN 105636734B
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
- B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0953—Monitoring or automatic control of welding parameters using computing means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/095—Monitoring or automatic control of welding parameters
- B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
- B23K9/1043—Power supply characterised by the electric circuit
- B23K9/1056—Power supply characterised by the electric circuit by using digital means
- B23K9/1062—Power supply characterised by the electric circuit by using digital means with computing means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
- B23K9/125—Feeding of electrodes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
Abstract
A kind of method for controlling welding system includes：The welding current of electrode is fed to the oblique variability control of an electric current；And the weldingvoltage of the welding current and change for being based at least partially on the control determines arc length.The arc length includes the distance between the electrode and workpiece, and the arc voltage includes the voltage between the electrode and the workpiece.
Description
Background technology
Present invention relates in general to welding system, and more particularly, it is related to control gas metal arc welding
(GMAW) welding system, also referred to as, pole noble gas protection (MIG) welding system.
Arc welding system generally includes power supply, and power supply is applied a current on electrode so that arc-through electrode and workpiece
Between, so as to heat electrode and workpiece to set up solder joint.In many systems, for example, gas metal arc welding system
(GMAW) in, electrode is made up of the welding wire fed by welding torch.Because by electric arc heated electrode, electrode melting is simultaneously combined in work
Forming solder joint in the fusing metal of part.
The MIG generations of the welding based on the pulse power in the source of welding current of advanced form, this is properly termed as pulse gas guarantor
Shield metallic arc welding (GMAW-P).That is, it is possible to achieve various pulsed systems, wherein by by power control circuit order
Current impulse and/or voltage pulse with adjust the metal drop from welding wire formation and deposition, maintain molten bath needed for heating
And cooling distribution and the short circuit between control welding wire and molten bath etc..
By controlling for voltage and current to be fed to electrode, GMAW system can be controlled by arc-melting and depositing electrode
Mode.Arc length between coordination electrode and workpiece can influence the energy for applying and/or how by arc deposited electricity
Pole.Some GMAW systems can be attempted being fed to the weldingvoltage of welding torch by control maintaining constant arc length.However,
Across the arc voltage of arc length may be only a part for the weldingvoltage between welding torch and workpiece.
The content of the invention
Outlined below and some embodiments of the scope identical of initial claimed invention.These embodiments not purport
In the scope of limitation claimed invention, but these embodiments are merely intended to provide the brief general of possible form of the invention
State.In fact, the present invention can include the various forms similar or different to embodiments set forth below.
In the first embodiment, a kind of method for controlling welding system includes：Electricity is fed to the oblique variability control of an electric current
The welding current of pole；And the weldingvoltage for being based at least partially in check welding current and change determines arc length.
The arc length includes the distance between the electrode and workpiece, and the arc voltage includes the electrode and the work
Voltage between part.
In another embodiment, a kind of welding system includes：Circuit for power conversion, it is configured to provide pulse welding
Waveform is to welding torch；One or more sensors；And the process circuit being connected with one or more of sensors.The pulse
Welding waveform includes peak fractions, and the peak fractions include ramp up portion or oblique deascension part.One or more of sensors
The weldingvoltage of the pulse welding waveform for being configured to sense on the electrode being applied in the welding torch and the pulse welding ripple
The welding current of shape.The process circuit is configured to be based at least partially in the ramp up portion or oblique deascension part phase
Between the change of the welding current and the change of weldingvoltage determine arc length.The arc length include the electrode with
The distance between workpiece.
In another embodiment, a kind of method for controlling welding system includes：The change of sensing pulse welding waveform
Welding current and the voltage of change；The voltage of the electric current and the change that are based at least partially on the change determines the electricity of electrode
Resistance；It is based at least partially on weldingvoltage, the resistance and drop electricity and falls to pressing determination arc voltage；And it is based at least partially on institute
The functional relation stated between arc length and the arc voltage controls arc length during the pulse welding waveform.It is described
Arc length includes the distance between the electrode and workpiece.
Brief description of the drawings
When being read in conjunction with the figure described further below, these and other features of the invention, aspect and advantage are would appreciate that,
Reference similar in accompanying drawing represents similar part in whole accompanying drawing, wherein：
Fig. 1 be a diagram that according to some aspects of this technology for performing the power supply that is connected with wire-feed motor of welding operation
The embodiment of GMAW system；
Fig. 2 is the embodiment of the control circuit block of the source of welding current of Fig. 1 shown types；
Fig. 3 is the embodiment of the welding arc between the electrode and workpiece intercepted along the line 3-3 of the GMAW system of Fig. 1；
Fig. 4 is the embodiment of the voltage and current waveform of GMAW system；
Fig. 5 is the diagram of the voltage and current of the sampling of the changing unit of the impulse waveform of GMAW system；
Fig. 6 is the diagram of the relation between arc length and λ according to embodiment；
Fig. 7 be a diagram that the flow of the method for obtaining the data group relevant with arc length and λ according to embodiment
Figure；And
Fig. 8 be for determining and control impulse waveform arc length method flow chart.
Specific embodiment
One or more specific embodiments of the invention explained below.In order to provide the accurate description of these embodiments,
All features of actual implementation method will not be described in this specification.It should be appreciated that researching and developing any this actual implementation method
When, such as in any engineering or design object, it is necessary to make numerous decisions specifically designed for implementation method to reach developer
Specific purposes, for example, it then follows the constraints that system is related and business is related, this may because implementation method it is different change
Become.Moreover, it will be appreciated that this development efforts may be complex and time-consuming, but the ordinary skill for being benefited from the disclosure
For personnel, this is probably the routine mission of design, manufacture and production.
Introduce various embodiments of the present invention when, article " one ", " one kind ", " being somebody's turn to do " and " described " have been intended to indicate that
The meaning of one or more elements.Term " including ", "comprising" and " having " be intended to inclusive, and expression can also have
There is the additional element in addition to the key element enumerated.
The embodiment of GMAW system as herein described can be based at least partially on the welding current and weldering for being fed to electrode
Connect the arc length that the change for sensing in voltage comes between coordination electrode and workpiece.GMAW system is (for example, pulsed GMAW system
System) control circuit can change to peak value of pulse or from peak value of pulse change during from sense voltage and current determination
Arc length.The weldingvoltage for being fed to electrode has multiple components, for example, the voltage of spaning electrode, drop-away voltage and across electric arc
The arc voltage of length.Arc voltage can be directly related with arc length.Control circuit using the welding current that observes and
Weldingvoltage is as the change (for example, during oblique ascension of pulse or oblique deascension) of the corresponding test data of various arc parameters is with logical
Cross and from weldingvoltage subtract the influence of other components and determine arc voltage.Control circuit can be from the oblique ascension of pulse or oblique deascension portion
The voltage and current sensed between by stages determines electrode resistance to determine the voltage of spaning electrode.Using control data and observe
Welding current and weldingvoltage, control circuit can determine drop-away voltage, arc voltage and arc length.Control circuit can be with
The arc length of determination and arc length are set for comparing, and control power supply and/or wire-feed motor with base at least in part
In it is determined that arc length and arc length setting between difference come adjust influence arc length arc parameters.Therefore, control
Circuit processed can determine arc length and arc length is controlled in closed-loop control.
Turning now to accompanying drawing, and referring first to Fig. 1, welding system is illustrated as including by conductor or conduit 14 each other
The power supply 10 and wire-feed motor 12 of connection.In the illustrated embodiment, power supply 10 and wire-feed motor 12 are separated so that wire-feed motor 12 can be with
It is located at a certain distance from power supply 10 near welding position.It is to be understood, however, that in some embodiments, can
With integrated with power supply 10.In these cases, conduit 14 will be in internal system.In the implementation that wire-feed motor 12 is separated with power supply 10
In example, terminal can be generally arranged in power supply 10 and wire-feed motor 12 to allow conductor or conduit 14 to be connected with system to allow electricity
Power and gas are provided to wire-feed motor 12 from power supply 10, and allow exchange data between both devices.
System is designed to provide welding wire, electric power and protective gas to welding torch 16.As the skilled person will appreciate
Like that, welding torch can have many different types, and allow generally for supply welding wire and gas to will form solder joint to connect
Close the position close to workpiece 18 of two or more metalworks.Second conductor (for example, fixture 58) usually extends to Welder
Part 18 is to supply the electric loop between power supply 10 and workpiece 18.
System is designed that operator, and number is selected especially by the operation interface 20 being arranged on power supply 10
According to setting (for example, welding parameter, arc length).During operation interface 20 generally brings the front panel of power supply 10 into, and can be with
Selection is allowed to set.Welding parameter can include arc parameters discussed below and systematic parameter.Systematic parameter can include the back of the body
Scape and peak point current and voltage, pulse frequency, pulse period etc..Arc parameters can include electrode size, type and material, send
Silk speed, protective gas composition etc..Specifically, welding system is designed that and welded using the various steel slotted by welding torch 16
The MIG welding of silk, aluminium welding wire or other welding wires.These welding parameters are passed to the control circuit 22 in power supply 10.System can
To be especially adapted to the weldering that implementation is designed to some electrode types (for example, solid electrode and/or medicine core electrode)
Junctor system.
Control circuit 22, is described more particularly below, and runs to control the generation of the weld power from the output of power supply 10, should
Weld power is applied to the welding wire of the welding operation needed for for performing.In some presently contemplated embodiments, for example, control
Circuit processed 22 can be adapted to adjust GMAW-P systems, and the GMAW-P systems maintain base between the tip of welding wire and workpiece 18
Constant arc length in sheet.For example, arc length can be maintained control circuit 22 threshold length of arc length setting
It is interior.Threshold length can be in about 1%, 5% or 10% of arc length setting.Control circuit 22 can determine to be arrived in offer
Arc length during the impulse waveform of welding torch 16, and controlled in same impulse waveform or follow-up arteries and veins by closed-loop control system
Arc length during rushing waveform.Control circuit 22 can not change (for example, inducing disturbance) impulse wave for measurement purposes
Voltage and current in the case of shape from the impulse waveform for sensing determines arc length, as described herein like that.Additionally,
In some embodiments, control circuit 22 can determine that electric arc is long during oblique ascension and before control impulse waveform to peaking
Degree.Control circuit 22 can sense the voltage between welding torch 16 and workpiece 18, and be based at least partially on the voltage across welding wire
Determine arc voltage and arc length one or more in change, negative electrode drop-away voltage and anode drop-away voltage.In some realities
Apply in example, control circuit 22 can instruct power supply 10 to provide impulse waveform and remain basic with during the peak fractions of impulse waveform
Above promote fusing metal to the short circuit transfer in the molten bath advanced while constant arc length.
In " short circuit " pattern, the molten drop of the material of fusing is formed on welding wire under the influence of the heating of welding arc,
And these molten drops are transferred to molten bath by the contact between welding wire and molten drop and molten bath or shorted period." pulse welding "
Or " pulse MIC welding " refers to the technology of the welding pool for producing pulse power waveform to control molten drop to deposit to advance.Such as
It is described herein, it is being produced by circuit for power conversion 24 and various GMAW can be used for by the impulse waveform that control circuit 22 is controlled
Transfer mode, includes, but not limited to short circuit transfer (for example, modulated metal deposit (RMD)), droplet transitions, splash transfer
With pulse transfer or their any combination.
Therefore control circuit 22 is connected with circuit for power conversion 24.The circuit for power conversion 24 is adapted to produce output work
Rate, for example, the impulse waveform being most applied at last on the welding wire at welding torch 16.Can be utilized in circuit for power conversion 24 various
Power conversion components, including but not limited to, chopper, booster circuit, reduction voltage circuit, inverter, converter, transformer etc..This
The configuration for planting circuit for power conversion 24 can have generally in this area and its type known per se.Circuit for power conversion 24 with
Electric power source is connected, as shown in arrow 26.The power being applied on circuit for power conversion 24 can be derived from power network, although can also
Using other power sources, for example, the work(that generator driven by the engine, battery, fuel cell or other alternate sources are produced
Rate.Finally, the power supply 10 shown in Fig. 1 includes interface circuit 28, and the interface circuit is designed that control circuit 22 and wire feed
Machine 12 exchanges signal.
Wire-feed motor 12 includes the complementary interface circuit 30 being connected with interface circuit 28.In certain embodiments, many pins connect
Mouth can be arranged on both parts 28,30, and multiconductor cable can extend to allow between respective interface circuit
Such as wire feed rate, technique, the electric current of selection, voltage, arc length or power are set on power supply 10, wire-feed motor 12 or both
The information such as level.
Wire-feed motor 12 also includes the control circuit 32 being connected with interface circuit 30.As described in more detail below, electricity is controlled
Road 32 allows to control wire feed rate according to the selection of operator, and allows these to be set by interface circuit 30 to feed back to power supply
10.Control circuit 32 is connected with the operation interface 34 in wire-feed motor 12, and the operation interface allows selection, and one or more weld ginseng
Number, particularly wire feed rate.Operation interface 34 can also allow for wire types, electric current, voltage, the electricity for selecting such as technique, utilizing
The welding parameter such as arc length degree or power setting.Control circuit 32 is also connected with gas control valve 36, and gas control valve regulation is arrived
The flow of the protective gas of welding torch 16.In general, this gas is provided in welding, and this gas can be before wire feed
Moment and/or welding after short time in open.The gas for being fed to gas control valve 36 is generally carried in the form of pressurized bottle
For as shown schematically at 38.
Wire-feed motor 12 is including being used for welding wire feeding to welding torch 16 under the control of control circuit 36 and is thus fed into
The part of welding application.For example, one or more bobbins 40 of welding wire are contained in wire-feed motor 12.Welding wire 42 unwinds from bobbin 40
And it is progressively fed welding torch 16.Bobbin 40 can be connected with clutch 44, and the clutch will be fed into welding torch in welding wire 42
Bobbin 40 is disengaged when 16.Clutch 44 can also be adjusted to maintain minimized friction level to avoid rotating freely for bobbin 40.
There is provided feed motor 46, the feed motor is engaged with feed rolls 48 and pushed away towards welding torch 16 from wire-feed motor 12 with by welding wire 42
It is dynamic.In practice, in roller 48 is mechanically connected with feed motor 46, and rotates to drive by feed motor 46
The dynamic welding wire 42 from wire-feed motor 12, while match roller 48 to be biased to maintain between two rollers 48 and welding wire 42 towards welding wire 42
Good contact.Some systems can include multiple such rollers 48.Finally, tachometer 50 can be set, and the tachometer is used
In detection motor 46, roller 48 or any other associated components speed to provide the instruction of actual wire feed rate.Carry out rotation
The signal of speed meter 50 is fed back to control circuit 36, for example, for calibrating.
It should be noted that other systems configuration and input scheme can also be implemented.For example, can be from outside wire-feed motor 12
Massive store container (for example, cylinder) or one or more bobbins 40 feeding welding wire 42.It is likewise possible to be arranged on from bobbin 40
" bobbin rifle " feeding welding wire 42 thereon or near welding torch 16.It is as described herein, can be by the operator in wire-feed motor 12
Operation interface 20 of input 34 or power supply 10 or both input wire feed rate setting.There is wire feed rate regulation on welding torch 16
In system, this can be the input for setting.
Power from power supply 10 is generally applied on welding wire 42 by welding cable 52 in a usual manner.Similarly, protect
Shield gas is fed by wire-feed motor 12 and welding cable 52.During welding operation, welding wire 42 is towards welding torch 16 by welding electricity
Cable jacket advances.In welding torch 16, extra traction motor 54 can be provided with associated driven roller, particularly for aluminium
Alloy welding wire.Trigger switch 56 on welding torch 16 provides feedback to wire-feed motor 12 and returns to power supply 10 to allow from wire-feed motor
By operator and stop welding process signal.That is, when trigger switch 56 is depressed, gas flowing starts, and welds
Silk 42 advances, and power is applied on welding cable 52 and is applied on the welding wire of advance by welding torch 16.Below it is also more detailed
These processes carefully are described.Finally, work piece cable and fixture 58 allow to be closed from electricity by welding torch, electrode (welding wire) and workpiece
The circuit in source maintaining welding arc during operation.
Fig. 2 illustrates the exemplary reality of the control circuit 22 for being designed to be worked in the system of the type of Fig. 1 diagrams
Apply example.Control circuit 22 includes operation interface discussed above 20 and interface circuit 28, and the interface circuit is used to pass parameter
It is delivered to downstream components and transmits the parameter from downstream components, downstream components is, for example, wire-feed motor 12, welding torch 16 and various biographies
Sensor and/or actuator.Control circuit 22 includes process circuit 62, and the process circuit itself can include that one or more are special
Or general processor, these processors be designed to perform welding system, in welding body system implement waveform calculate etc.
Deng.Process circuit 62 is associated with drive circuit 64, and the control signal from treatment is converted into being applied to work(by the drive circuit
Drive signal on the power electronic switching of rate change-over circuit 24.In general, drive circuit 64 pairs is from process circuit 62
These control signals react to allow circuit for power conversion 24 to produce the welding system for type described in the disclosure
Controlled waveform.Process circuit 62 will also be associated with storage circuit 66, and the storage circuit can include one or more type
Permanent and temporary data memory, for example, the welding system, storage welding parameter, storage welding for offer implementation set, deposit
Storage error log etc..
Fig. 3 is the reality of the welding arc 78 between the electrode 80 and workpiece 18 intercepted along the line 3-3 of the GMAW system of Fig. 1
Apply example.Curve map 82 illustrates the voltage between the contact point 84 in welding torch 16 and workpiece 18.It should be appreciated that electrode 80 is welding wire
42 one end extended from welding torch 16, the welding torch carries the impulse waveform from power supply 10.Welding torch 16 provides arteries and veins in contact point 84
Rush waveform to electrode 80.In certain embodiments, contact point 84 includes being connected to provide electric current and/or voltage with control circuit 22
The sensor of feedback.Impulse waveform has component of voltage and current component, and one or two components can be changed by power
Circuit 24 is controlled by controlling circuit 22.In contact point 84, there will be weldingvoltage (V relative to workpiece 18Welding) pulse
Waveform is applied on electrode 80.For example, in the peak fractions of impulse waveform, VWeldingAbout can be to be set by operation interface 20
Crest voltage.During the background parts of impulse waveform, VWeldingIt about can be the background electricity set by operation interface 20
Pressure.Voltage (the V of spaning electrodeEE) be based at least partially between the resistance of electrode 80, the contact point 84 of electrode 80 and tip 94
The temperature or their any combination of the length 86 (for example, electrode extension) of electrode 80 or electrode 80 are towards workpiece 18 along electricity
Pole 80 changes.In certain embodiments, VEEWith the substantially linear relationship change of length 86.In certain embodiments, such as Fig. 3 institutes
Show, VEEIn the Part I 90 close to end 88 than declining faster in the Part II 92 close to contact point 84.For example, electrode 80
Part I 90 can be hotter than Part II 92 and with resistance higher.
During welding procedure, the tip 94 of end 88 can be characterized as anode herein.In certain embodiments, point
End 94 is less than about 5 microns, 10 microns, 20 microns or 50 microns.Anode voltage (VAnode) electrode 80 can be based at least partially on
Type (for example, solid, medicine core), electrode material, the diameter of electrode 80, electrode feed rate or protective gas or they appoint
Meaning combination.In certain embodiments, VAnodeCan be substantially independent with respect to the welding current at tip 94.Electric arc 78
Across the arc length 96 between tip 94 and the surface district 98 of workpiece 18 (for example, IElectric arc) extend.Surface district 98 herein may be used
To be characterized as negative electrode.In certain embodiments, surface district 98 is less than about 5 microns, 10 microns, 20 microns or 50 microns.Negative electrode
Voltage (VNegative electrode) can be based at least partially on workpiece 18 material, joint categories, electrode feed rate or protective gas or they
Any combination.In certain embodiments, VNegative electrodeCan be substantially independent with respect to the welding current of surface district 98.
VAnodeAnd VNegative electrodeDrop-away voltage (V herein is properly termed as togetherDrop), and can be substantially independent relative to welding current
's.
As shown in figure 3, weldingvoltage V welding includes the multiple components shown in equation (1)：
VWelding=VEE+VAnode+VElectric arc+VNegative electrodeEquation (1)
In certain embodiments, VElectric arcLess than VWeldingAbout 10%, 15%, 20% or 25%.For example, in the peak pulse phase
Between 0.045 inch of low-carbon (LC) steel electrode fed with 400 feet per minutes, 90-10 argon gas-CO2Protective gas mixture, 0.75 inch
In electrode extension and 0.2 inch of embodiment of arc length, VWelding=32V, VEE=9V, VDrop=18V, and VElectric arc=
5V.(the l of arc length 96Electric arc) can be directly related to across IElectric arcArc voltage (V on 96Electric arc).Control circuit 22 is presently contemplated that
Embodiment can determine impulse waveform during VElectric arc, and using the V for determiningElectric arcControl VWeldingAnd by impulse waveform
Adjust to adjust IElectric arc96.In certain embodiments, control circuit 22 dynamically determines V during pulse welding is operatedElectric arc, to control
(the I of arc length 96 of the current and/or follow-up impulse waveform of systemElectric arc)。
Fig. 4 illustrates the exemplary voltage waveform 110 with voltage axis 112 implemented by the control circuit 22 of power supply 10
With the current waveform 114 with current axis 116, the two axles are across time shaft 118.The control control power conversion electricity of circuit 22
Electrode 80 is arrived in road 24 to supply voltage and current waveform 110,114 at contact point 84.Voltage waveform 110 can include areas of permanent pressure
Section, and current waveform 114 can include the section for allowing welding current to change during corresponding constant pressure section and according to work(
The speed of the substantial constant of the control of rate change-over circuit 24 makes the section of current ramp or oblique deascension.Impulse waveform can be with the cycle
120 frequency that is predetermined or setting is repeated.
Referring to voltage waveform 110, the first constant pressure section 122 represents background voltage level 124 is kept for constant period first
The background stage.On current waveform 114, it is allowed to which corresponding welding cable change is to maintain background electricity during the first background stage
Voltage levels 124.In exemplary voltage waveform 110, background voltage level 124 is sufficiently low so that in the first constant pressure section 122
Period is not short-circuited, and the sufficiently high end 88 with preheating electrode 80 forms electricity with before the rising of the voltage of succeeding impulse
The molten drop of pole material.Therefore, in various embodiments, background voltage level 124 changes in the range of about 17V to 20V,
But according to variable, for example, frequency, wire feed rate (WFS), peak voltage level 126, selection of electrode 80 etc., background voltage
124 can be with higher or lower.
Immediately after the first constant pressure section 122, the first background stage terminated and peak phase 136 starts.Power is changed
Circuit 24 makes welding current increase to peak current level 130 with peak point current ramp-up rate 128.Once welding current reaches peak
Value levels of current 130, circuit for power conversion 24 makes voltage increase reach peak voltage level 126 with during section 132, so that
Raised with voltage ramp speed 134.Voltage ramp speed 134 may be by order control, but by current waveform 114
What the resistance of order peak point current ramp-up rate 128 and electrode 80 was caused.Voltage may remain in peak voltage level 126, directly
Terminate to peak phase 136.During section 132, the Possible waves of welding current 114, and voltage 110 remains constant until peak value
Stage 136 expires.Peak voltage level 126, peak phase 136, peak point current ramp-up rate 128 and initial peak currents level
130 to can be selected so that and control l starting essentially upon while the electrode material for making fusing is shifted towards molten bathElectric arc96 Hes
VElectric arc。
Immediately began to for the second background stage after peak phase 136 expires.Welding current 114 is with electric current oblique deascension speed
138 decline, so as to cause voltage waveform 110 to reduce with voltage oblique deascension speed 140, until reaching background welding current level 142.
In order that voltage and the precision highest of welding current pulse, electric current oblique deascension speed 138 can be brighter than peak point current ramp-up rate 128
Show faster.In one embodiment, electric current oblique deascension speed 138 is 2000A/ms, is the peak point current ramp-up rate of 1000A/ms
128 twice.As during the first background stage, voltage then maintains background voltage level 124, and welding current is second
Change during the background stage.
The electrode material of fusing can remain attached to electrode 80 it is sophisticated when reach molten bath, so as to cause short circuit and
Temporarily extinguish electric arc 78.The point for crossing threshold voltage 146 in voltage drop 144 can detect short circuit, so as to trigger second back of the body
The scape stage terminates and ignition phase 148 starts again.During ignition phase 148 again, electric current can substantially in initial firing current again
Level 150 temporarily holds constant to allow to eliminate short circuit.Initial firing current level 150 can be with the sufficiently high electrode to keep fusing again
Material substantially fluid when it is transferred to molten bath.It should be noted that with the electrode material for melting from the end of electrode 80
Portion 88 separates and short circuit starts to eliminate, and naturally-occurring voltage raises 152；Substantially threshold voltage 146 is crossed in voltage and control
Circuit processed 22 detects the point generation restrike of arc 154 for having eliminated short circuit.Control circuit 22 can control welding current 114
To general context levels of current 142, and can be with control voltage 110 to general context voltage level 124 until the knot of cycle 120
Beam.
Control circuit 22 is based at least partially on from impulse waveform (for example, voltage waveform 110 and welding current waveform
114) calculating of measured value controls the (l of arc length 96 during impulse waveform as shown in Figure 4Electric arc).For the impulse waveform phase
Between time t, weldingvoltage (V can be determined from equation (2)Welding)：
VWelding(I (t)=REE*I(t)+(VAnode+VElectric arc+VNegative electrode) equation (2)
Wherein REEIt is the resistance of electrode 80.VWelding(I (t) and I (t) can be by the direct measurement value from sensor
And/or the control of circuit for power conversion 24 known value for controlling circuit 22.
As described above, VElectric arc(for example, because become in) arc length 96 can be directly related to (for example, VElectric arc=VElectric arc
(lElectric arc)).Therefore, equation 2 can be rewritten as equation (3)：
VWelding(I (t))=REE* I (t)+λ equatioies (3)
Wherein λ is limited by equation (4)：
λ=VDrop+VElectric arc(lElectric arc) equation (4)
Can be with the oblique ascension of peak phase 136 or the weldingvoltage during the oblique deascension of peak phase 136 and welding current
For determining electrode resistance REE.As shown in figure 5, when impulse waveform changes (for example, ramp up to peak phase 136 or
During the oblique deascension of peak phase 136), control circuit 22 can sample to welding current 182 and corresponding weldingvoltage 180.
In other embodiment, control circuit 22 can only sample rate current 180 and corresponding voltage 182 two points 184.Using a slope
Formula, control circuit 22 can determine R from equation (5)EE：
REE=(V2-V1)/(I2-I1) equation (5)
Wherein I1And V1It is during peak point current and voltage level (for example, respectively level 130 and 126) is ramped up to
First value of weldingvoltage and corresponding voltage, and I2And V2It is the welding during peak point current and voltage level is ramped up to
The second value of electric current and corresponding voltage.In certain embodiments, I1And V1It is during from peak point current and voltage level oblique deascension
Electric current and corresponding voltage first value；And I2And V2It is the welding electricity during from peak point current and voltage level oblique deascension
The second value of stream and corresponding voltage.In certain embodiments, the first value and second value can be sampled point 184 or sampled point
Interpolation between 184.
In certain embodiments, control circuit 22 can be to three or more points of electric current 180 and corresponding voltage 182
184 samplings, as shown in Figure 5.Control circuit 22 can determine the tropic 186 or provide the welding current values of multiple samplings with it is corresponding
Magnitude of voltage between functional relation other are approximate.Control circuit 22 can determine R using the functional relationEE.For example, figure
5 illustrate 0.045 inch of low-carbon (LC) steel electrode with 300 inches with it is per minute feeding and contact jaw operating distance (CTWD) be
Welding current 180 and voltage 182 in 0.8 inch of embodiment during the oblique ascension of peak phase.In this example, it is corresponding
The tropic 186 can be limited by equation (6)：
VWelding=18.27V+0.03521*IWeldingEquation (6)
Wherein REEIt is confirmed as 0.03521 Ω.Using equation (3) and from equation (5) or functional relation (for example, equation
(6)) the R for determiningEE, control circuit 22 can determine the value of λ, such as shown in equation (7)：
λ=V1-REE*I1Equation (7)
The data that control circuit 22 is based at least partially on from the loading of storage circuit 66 determine arc length (l from λElectric arc).Deposit
Storing up electricity road 66 can include database, and the database has the data tested and adjusted by one or many and obtained, these tests
With the λ and I that adjustment provides the various combinations for arc parametersElectric arcBetween corresponding relation.As described herein, arc parameters can
To include, but are not limited to, electrode type, electrode material, electrode size, electrode extension, wire feed rate, protective gas into
Point, welding torch type, CTWD, pulse frequency etc..The chart 200 of Fig. 6 illustrates the various λ values for combining 204 pairs with arc parameters
Arc length (the l for answeringElectric arc)202.For each chart or the group of data point 206, arc parameters can be divided into for data group base
Constant control arc parameters and the variable arc parameters for data group adjustment are maintained in sheet.For example, the chart 200 of Fig. 6
The data point 206 from sample sets is illustrated, wherein control arc parameters are electrode type, electrode material, electrode size and guarantor
Shield gas, and variable arc parameters include one or both of electrode extension and wire feed rate.In some embodiments
In, during the test of variable arc parameters or calibration welding is adjusted, by the vision measurement of arc length 202 (for example, passing through
Video) obtain data point 206.It is understood that the vision measurement value of arc length 202 is corresponding with λ value 204, and can be with
Determine λ value 204 with Fig. 5 and equation (3) to (7) as described above.
For the arc length (l of one group of arc parameters (for example, control arc parameters, variable arc parameters)Electric arc) 202 and λ
204 value can have functional relation.In certain embodiments, functional relation can be segmentation relation, wherein data point 206
Part I can be modeled with first function, and the Part II of data point 206 can be modeled with different second functions.Example
Such as, with the arc length (l more than about 0.1 inchElectric arc) 202 corresponding data points 206 can build with the first regression model 208
Mould, and with the arc length (l less than about 0.1 inchElectric arc) 202 corresponding data points 206 can use the second regression model 210
Modeling.Can be using two or more functional relations to one group of relationship modeling of data point 206.Further, it is to be appreciated that every
The model of individual segmentation relation can include, but are not limited to, linear model, multinomial model, logarithmic model and exponential model.
In some embodiments, a functional relation for all data points 206 of group can be with multinomial model 212 (for example, three ranks, four
Rank or five ranks or higher order) modeling or modeled by the interpolation between table data point.
Chart 200 is determined for the component of the λ 204 of this group control arc parameters (for example, VDropAnd VElectric arc)。VElectric arcDirectly
It is associated with lElectric arcSo that working as lElectric arcAt approximately equal to zero inch, VElectric arcApproximately equal to zero volt.Therefore, using equation (4) and chart
200 and/or functional relation, VDropCan be approximately equal in lElectric arcMagnitude of voltage 204 during value 202 approximately equal to zero is (for example, lElectric arcAnd voltage
The intercept of value 204).V drops can be in this group of data point 206 with the control arc parameters for maintaining and the variable arc parameters of regulation
Upper substantial constant, so as to allow to determine VElectric arc, and it is thus determined that this group of l of arc parametersElectric arc。
Storage circuit 66 can include the number of multiple charts 200 of the combination for multiple data groups and arc parameters
According to.In certain embodiments, control circuit 22 can be using one or more data group (for example, passing through interpolation) estimations VDrop、VElectric arc
And lElectric arc.For example, with an electrode size (for example, 0.045 inch diameter), protective gas composition (for example, 90% argon gas,
15%CO2) the corresponding data group of control arc parameters can be used for estimation have different size of electrode (for example, 0.05 English
Very little diameter) and/or different protective gas composition (for example, 85% argon gas, 15%CO2) control arc parameters VDrop、VElectric arcWith
lElectric arc.For determining VDrop、VElectric arcAnd IElectric arcTest or calibration data can be manually entered into and deposit with (for example, pass through operation interface 20)
In storing up electricity road 66, or loaded by input-output apparatus (for example, network, external memory storage).
Fig. 7 illustrates description for obtaining the data point 206 of data group or chart 200 to store in storage circuit 66
The flow chart of method 220.When method 220 starts, in operator's input (square frame 222) arc parameters to operation interface.One
In a little embodiments, input can be received in power supply or the single test controller being connected with power supply (for example, test terminal).Electricity
Arc parameter can include what the arc parameters substantially maintained during data group and the various welding for data group were adjusted
Variable arc parameters.For example, control arc parameters can include, but are not limited to, electrode type is (for example, solid, medicine core, sky
The heart), electrode material (for example, steel, aluminium), electrode geometry (for example, diameter), protective gas composition is (for example, argon gas, CO2、
Hydrogen, oxygen) and workpiece parameter (for example, workpiece material, joint categories).Variable arc parameters can include, but are not limited to,
Wire feed rate, electrode extension, CTWD and protective gas delivery rate.Operator is input into the pulse of (square frame 224) and supply
The relevant systematic parameter of waveform in operation interface, for example, passing through power operation interface.Systematic parameter can include, but not
It is limited to, background and peak point current and voltage, pulse frequency, peak pulse duration etc..
After the electric arc and systematic parameter of input data group, operator can perform (square frame 226) test welding.Test
Welding can include depositing to one or more molten drops one or more impulse waveforms in molten bath.During welding is tested, control
Circuit processed monitors welding current and weldingvoltage in welding current and weldingvoltage change (for example, oblique ascension, oblique deascension).Control electricity
Road is based at least partially on the welding current of observation and the regression model of weldingvoltage or the welding current with observation and welding
The point slope formula of voltage determines (square frame 228) REE, as described above.REECan be from the increase of observation or the welding current of reduction
Determine with welding voltage value.Using REE, observation welding current and weldingvoltage and equation (3), control circuit determine (side
Frame 230) VDropAnd VElectric arcSum as λ value.Arc length (the I of measurement (square frame 232) test weldingElectric arc), for example, by a high speed
Video.In certain embodiments, the video of test welding is then processed together with the welding current and weldingvoltage of observation, and
Arc length is measured after test welding is completed.Once measurement arc length, IElectric arcRemembered as data point 206 with corresponding λ
In record (square frame 234) data group.In certain embodiments, operator that (square frame 236) was adjusted before square frame 226 is returned to is variable
One or more in arc parameters are welded with performing next test.In addition, or in alternative solution, be connected with power supply
Control circuit or test controller (for example, computer) can be based at least partially on one group of instruction to adjust variable arc parameters
With the data group needed for the arc length for different λ values is obtained in the case of not stopping test welding.In other words, control
Circuit processed can perform data group and obtain instruction to automatically adjust variable arc parameters to constitute data group.It is understood that
Step in square frame 228,230,232 and 234 can be performed by the control circuit and/or test controller of power supply.At some
In embodiment, the multiple combination that can be directed to arc parameters performs method 220 to constitute and can add before the use of job site
It is downloaded to the database in storage circuit 66.
Fig. 8 is illustrated and determined using data and control the electricity during GMAW techniques (for example, short circuit, molten drop, splash, pulse)
The method 250 of arc length degree.Operator be input into (square frame 222) arc parameters and be input into (square frame 224) systematic parameter to power supply with/
Or the operation interface of wire-feed motor.Operator is also input into (square frame 252) arc length and is set to operation interface.It is understood that
Arc length can be associated with the heat and electrode that are input to electrode and workpiece to the welding quality of workpiece and transfer.Operation
Member can start (square frame 254) and supply welding procedure of the impulse waveform to welding torch.
Similar to method as described above 220, change (example of the control circuit for the power supplied during welding procedure
Such as, increase or reduce) monitoring welding current and weldingvoltage.Control circuit be based at least partially on change (for example, oblique ascension or
Oblique deascension) during observation welding current and weldingvoltage regression model or with observation welding current and weldingvoltage point
Slope formula determines (square frame 228) REE.Using REE, during changing observe welding current and weldingvoltage and equation
(3), control circuit determines (square frame 230) VDropAnd VElectric arcSum as λ value.Control circuit loads (square frame 256) from storage circuit
It is associated with the data of input arc parameters and input system parameter.In certain embodiments, control circuit is initiating (square frame 254)
Before welding procedure (square frame 256) data are loaded from storage circuit.It is understood that can be produced by the method 220 of Fig. 7
From the data of storage circuit loading.
Using one or more data groups loaded from storage circuit, circuit from λ and I is controlledElectric arcBetween functional relation it is true
Fixed (square frame 258) arc length.In some embodiments, λ and IElectric arcBetween functional relation be that different letters are had based on λ value
Several piecewise functions.In certain embodiments, λ and IElectric arcBetween functional relation be polynomial function (for example, three ranks).From λ
When determining arc length, control circuit determine arc length that (square frame 260) determines from square frame 258 with from the determination of square frame 252
Difference between arc length setting.Control circuit controls (square frame 262) power supply and/or wire-feed motor with least in closed-loop control
It is based in part on arc length difference regulation arc length.For example, control circuit can control circuit for power conversion and/or wire feed
Machine is adjusting current waveform (for example, background current, peak point current, duration of peak value, ramp-up rate, oblique deascension speed), voltage
Waveform (for example, background voltage, crest voltage, duration of peak value, ramp-up rate, oblique deascension speed), pulse frequency, pulse week
One or more in phase, electrode extension and wire feed rate, so as to adjust current impulse waveform or succeeding impulse waveform
Arc length.
Control circuit determines in closed-loop control system and controls arc length.In certain embodiments, control circuit can
To perform step 228,230,256,258,260 and 262 within the pulse period, so as to allow control circuit control to be fed to welding torch
Each impulse waveform arc length.For example, control circuit can monitor a series of the first impulse waveform in impulse waveforms
Welding current and weldingvoltage, it is determined that the arc length when the peak phase of the first impulse waveform starts, and first
Impulse waveform controls the arc length of the first impulse waveform before terminating.In certain embodiments, control circuit can utilize come
From the first impulse waveform (for example, the arc length of waveform n) controls succeeding impulse waveform (for example, waveform n+1, n+2, n+3, n
+ ... etc.) length.
In certain embodiments, control circuit as described above allows to control electric arc long independently of electrode extension
Degree.Arc length is controlled independently of electrode extension can allow operator to be formed in relatively deep joint with needed for
The welding of arc length.In certain embodiments, control circuit can be based at least partially on the change determination weldering of arc length
Abrasion on the contact point of torch.For example, the contact point that impulse waveform is delivered to the abrasion of electrode can partly be fused to electricity
Extremely go up and stop or slow down electrode towards the feeding of workpiece.It is this it is partially fused can be by from the first impulse waveform to second
One or more liquid-drop diameters (for example, threshold difference) of impulse waveform change arc length.Accordingly, it is determined that this of arc length
Planting change can indicate the contact point of abrasion of welding torch.Control circuit can notify operator (for example, passing through by operation interface
Alarm signal) abrasion contact point.
In certain embodiments, control circuit can be based at least partially on the electricity for determining in equation (5) as described above
The resistance of pole determines electrode extension and/or CTWD.For example, control circuit can be by electrode extension and electrode resistance
Between functional relation (for example, for known electrode diameter, Ω/mm) determine electrode extension.By by the first pulse
The resistance determined during waveform and succeeding impulse waveform comparison, control circuit can determine the degree of wear of the contact point of welding torch
And/or type.Control circuit can utilize statistical analysis with the resistance of the determination of relatively more multiple impulse waveforms, and determine electrode
The abrasion of extension elongation, CTWD or contact tip or their any combination.In certain embodiments, control circuit can at least portion
Ground is divided to determine the infiltration of electrode or molten bath through workpiece based on the resistance, electrode extension that determine or CTWD.For example, maintaining
During the resistance increased during substantially invariable CTWD can represent that electrode extension is increasing and molten bath is just infiltrating through workpiece.
Therefore, control circuit can monitor index of the resistance as infiltration.
Put it briefly, control circuit monitors impulse waveform for electric current and/or voltage change (for example, increase or reduction),
The electric current and/or voltage change can represent that peak phase starts, peak phase terminates or other changes.Observing electric current
And/or during voltage change, control circuit can utilize the electric current and magnitude of voltage of the sampling from change oblique from regression model or point
Rate formula determines REE.Once it is determined that REE, control circuit to determine λ using the current value of the voltage and sampling of equation (3) and sampling
Value.In certain embodiments, control circuit can control impulse waveform to be based solely on λ regulation arc lengths.It is based solely on λ's
Regulation allows control circuit in regulation VDropAnd VElectric arcWhen compensate VEEChange (for example, due to electrode extension).In addition, or
In alternative solution, control circuit can determine I from λ and from one or more data groups of storage circuit loadingElectric arc, described one
Individual or multiple data groups are associated with the arc parameters of current welding at least in part.It is being based at least partially on IElectric arcDetermination
Closed-loop control in, control circuit can control power supply and/or power feeder to adjust current PRF waveform and/or current welding
Succeeding impulse waveform VElectric arcWith corresponding IElectric arc。
Although having illustrated and having described only some features of the invention herein, those skilled in the art will
Make many modifications and variations.It is understood, therefore, that appended claims are intended to fall into true spirit of the invention
In the range of all this modifications and variations.
Element list
10 power supplys
12 wire-feed motors
14 conduits
16 welding torches
18 workpiece
20 operation interfaces
22 control circuits
24 circuit for power conversion
26 arrows
28 interface circuits
30 complementary interface circuits
32 control circuits
34 operation interfaces
36 gas control valves
38 references
40 bobbins
42 welding wires
44 clutches
46 feed motors
48 feed rolls
50 tachometers
52 welding cables
54 extra traction motors
56 trigger switch
58 fixtures
62 process circuits
64 drive circuits
66 storage circuits
78 welding arcs
80 electrodes
82 curve maps
84 contact points
86 length
88 ends
90 Part I
92 Part II
94 tips
96 arc lengths
98 surface districts
110 voltage waveforms
112 voltage axises
114 current waveforms
116 current axis
118 across time shaft
120 cycles
122 first constant voltage sections
124 background voltage levels
126 peak voltage levels
The oblique variability of 128 peak point currents
130 peak current levels
132 sections
134 speed
136 peak phase times
The oblique variability of 138 background currents
140 drawing reference numerals
142 background current levels
144 voltage drops
146 threshold voltages
148 ignition phases again
150 initial firing current levels again
152 voltages increase
154 restrike of arcs
180 electric currents
182 corresponding voltages
184 points
186 tropic
200 charts
204 γ values
206 data points
202 arc lengths
208 first regression models
210 second regression models
212 multinomial models
220 methods
222 square frames
224 square frames
226 square frames
228 square frames
230 square frames
232 square frames
234 square frames
236 square frames
250 methods
252 square frames
254 square frames
256 square frames
258 square frames
260 square frames
262 square frames
Claims (31)
1. it is a kind of control welding system method, including：
Within a period of time, control to be fed to the welding of electrode with the oblique variability of an electric current by the control circuit of the welding system
Electric current；And
During described a period of time, the arc voltage for being based at least partially on the in check welding current and change passes through
The control circuit determines arc length, wherein the arc length includes the distance between the electrode and workpiece, the electricity
Arc voltage includes the voltage between the electrode and the workpiece, and is not changing the welding current for measurement purposes
In the case of determine the arc length.
2. method according to claim 1, including：
During described a period of time, sensed by one or more sensors for being connected to the control circuit described controlled
Welding current and the change arc voltage；And
The arc length for being based at least partially on the determination controls one or more welding parameters of the welding system.
3. method according to claim 2, including：
During the oblique ascension of the first pulse, by one or more of sensors sense the in check welding current and
The arc voltage of the change；And
During the second pulse after first pulse, one or more of welding are controlled by the control circuit
Parameter, wherein one or more of welding parameters include the arc length, wire feed rate or electrode extension or they
Any combination.
4. method according to claim 1, wherein determining that the arc length includes：
During described a period of time, the arc voltage of the in check welding current and the change is based at least partially on
The resistance of the electrode is determined by the control circuit；
It is based at least partially on weldingvoltage, the resistance and drop-away voltage and the electric arc electricity is determined by the control circuit
Pressure；And
The functional relation being based at least partially between the arc length and the arc voltage is true by the control circuit
The fixed arc length.
5. method according to claim 4, including：
It is input into by operator interface receiving electrode parameter and protective gas is input into；
It is based at least partially on the electrode parameter input and protective gas input loads the functional relation from memory.
6. method according to claim 2, wherein controlling one or more of welding parameters to be included in the first pulse period
Between by the arc length maintain needed for arc length threshold length in.
7. method according to claim 1, including：
During described a period of time, the arc voltage of the in check welding current and the change is based at least partially on
The resistance of the electrode is determined by the control circuit；
The functional relation being based at least partially between the resistance and the electrode extension is true by the control circuit
Fixed electrode extension elongation.
8. it is a kind of control welding system method, including：
The welding current of the change of waveform and the voltage of change are welded by one or more sensor sensing pulses, wherein described
There is the ramp up portion in the pulse of the pulse welding waveform or oblique deascension portion in the welding current of change and the voltage of the change
Between by stages；
It is based at least partially on the upward of during the ramp up portion welding current of the change and the voltage of the change
Slope, during the oblique deascension part the downward slope of the welding current of the change and the voltage of the change, in institute
The upward regression model of the welding current of the change and the voltage of the change or in the oblique deascension during stating ramp up portion
The downward regression model of the welding current of the change and the voltage of the change, one by being connected to during part
Or the control circuit of multiple sensors determines the resistance of electrode；
It is based at least partially on weldingvoltage, the resistance and drop-away voltage and arc voltage is determined by the control circuit；And
And
The functional relation between the arc length and the arc voltage is based at least partially on by the control circuit control
Make the arc length during the pulse welding waveform, wherein the arc length include between the electrode and workpiece away from
From.
9. method according to claim 8, including：
Receive threshold length；And
In the threshold length of the arc length needed for the arc length is maintained during the pulse welding waveform.
10. method according to claim 8, wherein the functional relation is at least partially based on the institute provided by welding torch
State the material and protective gas of electrode.
A kind of 11. methods for controlling welding system, including：
The welding current of electrode is fed to the oblique variability control of an electric current；
The arc voltage for being based at least partially on the in check welding current and change determines arc length, wherein the electricity
Arc length degree includes the distance between the electrode and workpiece, and the arc voltage is included between the electrode and the workpiece
Voltage.
12. methods according to claim 11, including：
Sense the arc voltage of the in check welding current and the change；And
The arc length for being based at least partially on the determination controls one or more welding parameters of the welding system.
13. methods according to claim 12, including：
The arc voltage of the in check welding current and the change is sensed during the oblique ascension of the first pulse；And
One or more of welding parameters are controlled during the second pulse after first pulse, wherein one
Or multiple welding parameters include the arc length, wire feed rate or electrode extension or their any combination.
14. methods according to claim 12, wherein controlling one or more of welding parameters including at least in part
Arc length based on the determination utilizes closed-loop control.
15. methods according to claim 11, wherein determining that the arc length includes：
The arc voltage for being based at least partially on the in check welding current and the change determines the resistance of the electrode；
It is based at least partially on weldingvoltage, the resistance and drop-away voltage and determines the arc voltage；And at least in part
The arc length is determined based on the functional relation between the arc length and the arc voltage.
16. methods according to claim 15, including：
Receiving electrode parameter is input into and protective gas input；
It is based at least partially on the electrode parameter input and protective gas input loads the functional relation from memory.
17. methods according to claim 12, wherein controlling one or more of welding parameters to be included in whole first
In the threshold length of the arc length needed for the arc length is maintained during pulse.
18. methods according to claim 11, including：
The arc voltage for being based at least partially on the in check welding current and the change determines the resistance of the electrode；
The functional relation being based at least partially between the resistance and the electrode extension determines electrode extension.
A kind of 19. welding systems, including：
Circuit for power conversion, the circuit for power conversion is configured to provide pulse welding waveform to welding torch, wherein the pulse
Welding waveform includes peak fractions, and the peak fractions include ramp up portion or oblique deascension part；
One or more sensors, the sensor is configured to sense the pulse on the electrode being applied in the welding torch
Weld the weldingvoltage of waveform and the welding current of the pulse welding waveform；And
Process circuit, the process circuit is connected with one or more of sensors, wherein the process circuit is configured to
It is based at least partially on the change and the welding of the welding current during the ramp up portion or the oblique deascension part
The change of voltage determines arc length, wherein the arc length includes the distance between the electrode and workpiece.
20. welding systems according to claim 19, wherein the process circuit is configured to be based at least partially on
It is the upward slope of the welding current and the weldingvoltage during the ramp up portion, described during the oblique deascension part
The downward slope of welding current and the weldingvoltage, the welding current and welding electricity during the ramp up portion
Pressure upward regression model or during the oblique deascension part welding current and the weldingvoltage downward recurrence
Model determines arc length.
21. welding systems according to claim 19, wherein the process circuit is configured to be based at least partially on institute
State the peak fractions that arc length controls the pulse welding waveform.
22. welding systems according to claim 19, wherein the process circuit includes memory, and the treatment electricity
The functional relation that road is configured to be based at least partially between arc voltage and the arc length determines the arc length,
Wherein described functional relation storage is in the memory, and the arc voltage is included between the electrode and the workpiece
Voltage.
23. welding systems according to claim 19, wherein the process circuit is configured to control the power to change
Circuit is with the threshold length of the arc length needed for the arc length is maintained during the whole pulse welding waveform
It is interior.
24. welding systems according to claim 23, including the operator indicator being connected with the process circuit, wherein
The process circuit is configured to send alarm signal to institute if the arc length of the determination is more than the threshold length
State operator indicator.
25. welding systems according to claim 19, wherein the process circuit is configured to be based at least partially on institute
The drop-away voltage and arc voltage stated between electrode and the workpiece control the arc length.
26. welding systems according to claim 25, wherein the drop-away voltage is based at least partially on the electrode
Material, the protective gas of offer to the welding torch or their any combination.
27. welding systems according to claim 19, wherein the process circuit is configured to be based at least partially on institute
The arc length for stating determination controls one or more welding parameters, wherein the welding parameter includes that wire feed rate, electrode are stretched out
Length or their any combination.
28. welding systems according to claim 20, wherein the process circuit is configured to be based at least partially on institute
State upward slope, the downward slope, the upward regression model or the downward regression model and determine electrode electricity
Resistance, and the process circuit is configured to be based at least partially on the electrode resistance and determines the arc length.
A kind of 29. methods for controlling welding system, including：
The welding current and the voltage of change of the change of sensing pulse welding waveform；
The voltage of the welding current and the change that are based at least partially on the change determines the resistance of electrode；
It is based at least partially on weldingvoltage, the resistance and drop-away voltage and determines arc voltage；And
The functional relation being based at least partially between the arc length and the arc voltage controls the pulse welding ripple
Arc length during shape, wherein the arc length includes the distance between the electrode and workpiece.
30. methods according to claim 29, including：
Receive threshold length；And
In the threshold length of the arc length needed for the arc length is maintained during the whole pulse welding waveform.
31. methods according to claim 29, wherein the functional relation is based at least partially on the institute provided by welding torch
State the material and protective gas of electrode.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US14/067,432 | 2013-10-30 | ||
| US14/067,432 US9539662B2 (en) | 2013-10-30 | 2013-10-30 | Extraction of arc length from voltage and current feedback |
| PCT/US2014/045872 WO2015065542A1 (en) | 2013-10-30 | 2014-07-09 | Extraction of arc length from voltage and current feedback |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN105636734A CN105636734A (en) | 2016-06-01 |
| CN105636734B true CN105636734B (en) | 2017-06-30 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201480056382.8A Active CN105636734B (en) | 2013-10-30 | 2014-07-09 | From the system and method that voltage and current feedback extracts arc length |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US9539662B2 (en) |
| EP (1) | EP3062950B1 (en) |
| KR (1) | KR102222977B1 (en) |
| CN (1) | CN105636734B (en) |
| BR (1) | BR112016006725A2 (en) |
| CA (1) | CA2921695C (en) |
| MX (1) | MX359250B (en) |
| WO (1) | WO2015065542A1 (en) |
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Also Published As
| Publication number | Publication date |
|---|---|
| MX2016002123A (en) | 2017-01-05 |
| BR112016006725A2 (en) | 2017-08-01 |
| CA2921695C (en) | 2019-06-25 |
| CA2921695A1 (en) | 2015-05-07 |
| KR102222977B1 (en) | 2021-03-03 |
| EP3062950A1 (en) | 2016-09-07 |
| US20150114940A1 (en) | 2015-04-30 |
| WO2015065542A1 (en) | 2015-05-07 |
| CN105636734A (en) | 2016-06-01 |
| KR20160077056A (en) | 2016-07-01 |
| EP3062950B1 (en) | 2024-02-07 |
| US9539662B2 (en) | 2017-01-10 |
| MX359250B (en) | 2018-09-20 |
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